Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective
Abstract
:1. Introduction
- Greater efficiency. Traditional manufacturing methods often waste materials due to the need for cutting and forming. Three-dimensional printing allows materials to be applied precisely in layers, minimizing waste. The 3D printing process can be faster than traditional manufacturing methods, resulting in shorter production cycles [21].
- Shorter supply chains. AM makes it possible to reduce the need to transport products over long distances and streamline the supply chain by reducing the need for large inventories. Instead, parts can be produced on demand, minimizing inventory costs and waste. This is particularly beneficial for the maintenance of spare parts in the energy industry. Additive manufacturing is widely used in the production of components for renewable energy systems such as wind turbines and solar panels. This includes the manufacture of turbine blades, housing structures, and specialized components that improve the overall performance of renewable energy systems. Local manufacturing helps to reduce transportation-related greenhouse gas emissions [21].
- Greater design freedom. Three-dimensional printing enables the creation of complex structures and geometries that are difficult or impossible to achieve with traditional manufacturing methods [22,23], thus providing a high degree of customization [24,25]. Lightweight components that can be used in a variety of energy applications, including aerospace, renewable energy, and transportation, thus contributing to improved energy efficiency, particularly in sectors such as aviation and electric vehicles.
- The ability to easily print replacement parts [26]. Producing custom and complex components tailored to specific energy applications. This is particularly valuable for developing parts for energy systems with unique requirements.
- Three-dimensional printing often has lower production costs per part, especially for low volumes [27]. Three-dimensional printing facilitates rapid and low-cost prototyping, allowing engineers to test and refine designs faster and more cost effectively than with traditional manufacturing methods. This supports the design and innovation process.
- The potential of relevant open source technology [33].
Designing for 3D Printing
2. The Promises of 3D Printing to Optimize Heat Transfer
2.1. Better/Worse Heat Transfer Due to Complex Geometries and Internal Structures
Complex Geometries for Better Heat Transfer
2.2. Selecting Materials
2.3. Lightweight Design and Geometry Optimization
2.4. Localized Production
2.5. Heat Exchangers Using 3D Printing Technology
2.6. Integration with Renewable Energy Systems
3. Challenges of 3D Printing Technology in the Context of Sustainability
- Many current 3D printing materials are based on plastics, which can cause pollution and are difficult to recycle. There is an urgent need to develop more sustainable materials, such as those that are biodegradable or based on renewable resources. Recycling processes for these materials must be made more efficient and widely available to minimize their negative impact on the environment.
- The generation of excessive waste and energy consumption during the 3D printing process can be detrimental to sustainability. Research into new methods and technologies that minimize waste and energy consumption is essential.
- Future research should focus on improving the sustainability of AM technology by developing lower-energy powder manufacturing technologies, analyzing the impact of key parameters (such as specific energy consumption, build rate, powder yield, etc.) on the life cycle assessment of the AM process, optimizing key parameters for an efficient result, and increasing the production speed of the AM process. This will also improve the economics of the AM process by reducing the cost of producing the required parts [277].
- As 3D printing grows in popularity, there is a need to ensure the scalability of manufacturing processes and the availability of suitable raw materials. It is important to ensure that raw materials are ethical, sustainable and do not lead to the depletion of natural resources.
- The use of 3D printing in some sectors, such as medicine or aerospace, may require compliance with strict safety standards and norms, posing a challenge for the technology.
- Many people, both consumers and businesses, may not be aware of the potential benefits and challenges of 3D printing in the context of sustainability. Education and awareness are key to the sustainable adoption of 3D printing technology.
- The lack of consistent standards and regulations for 3D printing can make it difficult to control the technology’s environmental impact. Establishing consistent standards for sustainable 3D printing is essential. Developing 3D printing with these challenges in mind can help to create more sustainable and environmentally friendly practices in the manufacturing industry. Separately, research into additive manufacturing applied to process/chemical engineering is a rapidly growing field. As technology advances and environmental awareness increases, it is expected that these challenges will be addressed and contribute to the further development of sustainable solutions in the field of 3D printing.
4. Conclusions
Funding
Data Availability Statement
Conflicts of Interest
Nomenclature
AM | Additive manufacturing |
CAD | Computer-aided design |
CAM | Computer-aided manufacturing |
CGDS | Cold gas dynamic spray |
DMLS | Direct metal laser sintering |
FDM | Fused deposition modeling |
LCM | Lithography-based ceramic manufacturing |
LIGA | Lithography, electroplating, and molding |
LOM | Laminated object manufacturing |
LPBF | Laser powder bed fusion |
LPW | Laser polymer welding |
SLM | Selective laser melting |
SLS | Selective laser sintering |
UAM | Ultrasonic additive manufacturing |
SLA | Stereolithography |
DIW | Direct inkjet writing |
R2R | Roll-to-roll |
IL | Imprint lithography |
EFF | Extrusion free forming |
DED | Directed energy deposition |
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Names Structures | Equation | Visualization |
---|---|---|
Gyroid [52] | sin(x)cos(y) + sin(y)cos(z) + sin(z)cos(x) | |
Schwarz [53] | cos(x) + cos(y) + cos(z) | |
Neovilius [54] | 3 × cos(x) + cos(y) + cos(z) + 4 × cos(x) × cos(y) × cos(z) | |
Diamond [55] | sin(x) × sin(y) × sin(z) + sin(x) × cos(y) × cos(z) + cos(x) × sin(y) × cos(z) + cos(x) × cos(y) × sin(z) | |
Lidinoid [54] | sin(2 × x) × cos(y) × sin(z) + sin(2 × y) × cos(z) × sin(x) + sin(2 × z) × cos(x) × sin(y) − cos(2 × x) × cos(2 × y) − cos(2 × y) × cos(2 × z) − cos(2 × z) × cos(2 × x) + 0.3 | |
Split P [55] | 1.1 × (sin(2 × x) × sin(z) × cos(y) + sin(2 × y) × sin(x) × cos(z) + sin(2 × z) × sin(y) × cos(x)) − 0.2 × (cos(2 × x) × cos(2 × y) + cos(2 × y) × cos(2 × z) + cos(2 × z) × cos(2 × x)) − 0.4 × (cos(2 × x) + cos(2 × y) + cos(2 × z)) |
Sector | Application | Optimization of Heat Flow | References |
---|---|---|---|
Electronics cooling | Heat sinks with complex structure | Microchannels or fins—heat dissipation. | [73,81,82] |
Aerospace Industry | Components with integrated cooling channels | Internal cooling channels in the aerospace structures of components, improving resistance to high temperatures | [83,84,85] |
Production of wind turbines | Optimization of the blades | Optimizing the shape of wind turbine blades to increase efficiency and minimize drag | [86,87] |
Nuclear Energy | Components for optimizing heat flow in reactors | Internal moderator components for heat transfer improvement in nuclear reactors. | [88,89] |
Automotive Industry: | Engine Cooling | Designing engine radiators with a more complex structure to increase cooling efficiency. | [90,91] |
Liquid cooling in electronics | Custom Cooling Channels | Custom cooling channels for liquid cooling systems tailored to specific electronics configurations | [92,93] |
Production of heat exchangers: | Channel geometry optimization | Design and manufacture heat exchangers with optimal channel geometry that improves heat transfer efficiency | [61,94,95] |
Heatsink design optimization | Custom radiators with complex shapes | Design heatsinks with custom geometry, tailored to the specific application and mounting space | [96,97,98] |
Cooling in the Apparel Industry | Microchannels in textiles | Creation of microchannel structures that improve ventilation and cooling in sports or specialty apparel | [99,100,101,102] |
Type | Material | Characteristic | Application | References |
---|---|---|---|---|
Heat conductive materials | Copper, aluminum, steel | Excellent thermal conductivity | Manufacture of heat sinks or cooling components | [34,103,104,105] |
Graphene | Excellent thermal conductivity properties | Graphene nanoparticles or graphene composites added to other 3D-printed materials to improve their thermal conductivity. | [106,107,108] | |
Engineering polymers | PEEK Polyetheretherketone | A thermoplastic polymer with high mechanical strength and chemical resistance | Manufacture of industrial components where both thermal and mechanical properties are important | [109,110,111] |
Nylon | Good mechanical properties, relatively light | Production of components where the balance between mechanical strength and thermal conductivity efficiency is important | [112,113,114,115] | |
Metallic materials | Aluminum alloy | Lightweight metal with good thermal conductivity | Production of cooling components such as heat sinks | [103,104,105] |
Aluminum with addition of other materials | Components with special thermal properties | [116] | ||
Ceramics | Aluminum oxide | High heat resistance and excellent thermal properties | Manufacturing components that require efficient heat transfer under extreme conditions | [117,118] |
Hybrid materials | Carbon fiber composites | The lightness of polymers with the high thermal conductivity of carbon fibers | Both thermal and mechanical properties are important | [119,120,121,122] |
Metal–polymer composites | A combination of thermal conductivity and flexibility | Advantageous in certain applications | [123,124,125,126] |
3D Printing | Materials | Advantages | References |
---|---|---|---|
SLM | 316L stainless steel, 6061 aluminum | -The complex ribbed surface of the micro heat exchanger -The exchangers performed consistently. | [154] |
-Experimental determination of the heat transfer characteristics and pressure drops of the four heat sinks. -The study showed an increase in the performance of the studied exchangers. | [155] | ||
Aluminum 6061, stainless steel 316L | -Three heat sinks with a ribbed structure -Better performance than conventional heatsinks -New geometries result in lower pressure drop | [156,157] | |
AlSi10Mg Ti6Al4V | -Cylindrical geometry for internal channels built at different angles -Surface roughness of internal channels varies with angle of construction | [158] | |
-Oil Cooler -Structure will transfer 15 kW of heat under design conditions | [159] | ||
Stainless steel 316, stainless steel 316L | Type 316 stainless steel printed tubes have higher mechanical strength and lower ductility than annealed Type 316L stainless steel. | [160] | |
-Oil cooler fabricated. -Unique features include lenticular tubes with offset strip fins and angled plate-fins. | [161] | ||
DMLS | AlSi10Mg | -DMLS can be used with a new type of alloy to create porous lattice structures. | [162] |
-Rough surfaces and ribbed surfaces had an average of 63% and 35% better convective heat transfer, respectively, than smooth surfaces. | [147] | ||
-Collector–microchannel heat exchanger -The collector–microchannel geometry offers a significant improvement over the state of the art. | [163] | ||
Titanium alloy | -Air-to-water heat exchangers using a microchannel collector design have shown a 45–100% increase in base conductivity and a 15% increase in heat transfer coefficient for the same pressure drop compared to corrugated surfaces. | [77] | |
-Friction coefficients increased due to the higher ratio of roughness to hydraulic diameter. -Machined channels have relatively comparable thermal performance to grooved channels. | [164] | ||
-Three samples of corrugated channels, each containing channels of different wavelengths, were designed and additively fabricated to evaluate the pressure loss and heat transfer performance of the channels. | [165] | ||
-Cylindrical channels were built in three different orientations, while teardrop and rhombic channels were built horizontally. -Channels built vertically had the lowest coefficient of friction, while channels built diagonally had the highest coefficient of friction. | [166] | ||
-A heat transfer correlation is presented that translates the Nusselt number of flow through DMLS microchannels based on predictions or friction coefficient measurements. | [164] | ||
-The process of improving the thermal performance of a twisted shell-and-tube heat exchanger using CFD modeling and extended AM fabrication space is presented. -A 40% increase in heat transfer coefficient was modeled. | [167] | ||
-Oil cooler -The weight and volume of the heat exchanger is 66% and 50% less, respectively, than a fuel-cooled oil cooler of similar capacity and performance. | [168] | ||
Stainless steel, titanium alloy, aluminum | -Three prototype air-to-water heat exchangers in a power plant -Improved gravimetric heat transfer density compared to a corrugated fin heat exchanger. | [169] | |
LPBF | -Bare tube heat exchanger. -Achieves a ~20% reduction in size, a ~20% reduction in air pressure, a ~40% reduction in material volume, and a ~2% reduction in surface area compared to a micro-channel heat exchanger. | [133] | |
Ti-6Al-4V | -L-PBF used to fabricate a Ti-6Al-4V multilayer oscillating heat pipe (ML-OHP) -The thermal performance of ML-OHP is characterized. | [170] | |
Wire-Arc Spraying | -Dense 625 alloy was deposited on the surface of 10 pores per inch (PPI) and 20 PPI nickel foam sheets to produce compact heat exchangers. | [171] | |
CGDS | aluminum nickel stainless steel 34 | -The 20 PPI foam exhibited higher flow resistance and heat transfer than the 10 PPI foam due to its smaller pore size and larger internal surface area. | [172] |
-The effect of changing the fin height and density of the pyramidal fins has been studied. -Increasing the height or density of the fins also increases the overall thermal conductivity at the expense of higher pressure drop. at the expense of higher pressure drop. | [173] | ||
-Two new fin geometries were created; pyramidal and trapezoidal. -The two new geometries have better heat transfer performance than traditional rectangular fins, but higher pressure drop. | [174] | ||
-Pyramidal rib arrays were fabricated with varying volume fractions of aluminum and alumina. -The use of aluminum-alumina powder as an alternative to pure aluminum eliminates the need for expensive polymer nozzles that wear out quickly. | [175] | ||
-Produces near-net-shape pyramidal fin arrays in a variety of materials, including aluminum, nickel and Class 34 stainless steel. | [176] | ||
-Pyramidal Ribs -Classic double recirculation and flow bypass structures observed in areas of trailing ribs. | [177] | ||
-Pressure drops and convection coefficients for square, round, and diamond fins. -Alternating configurations produce higher convection coefficients and higher pressure drop.. | [178] | ||
LIGA | -The cross-flow micro heat exchanger was developed to provide a function similar to that of a car radiator. -The micro heat exchanger demonstrated a good ratio of heat transfer rate to volume. | [179] | |
LPW | -Air-to-water heat exchanger -The polymer heat exchanger required 85% less weight but 35% more volume than a corrugated metal heat exchanger of the same capacity. -COP increased by 27%. | [126] | |
-Microfluidic channels in the fins of the liquid-liquid heat exchanger. -The walls, which were 0.032 mm to 0.1 mm thick, could be carefully cleaned, but they deformed slightly under pressure. | [180] | ||
Polyjet | -Air–water heat exchanger. -The thin wall (150 μm) reduces the thermal resistance of the wall to only 3% of the total thermal resistance. | [181] | |
FDM | -Air-to-water heat exchanger -Improving the thermal conductivity of the printed polymer directly affects the performance of the heat exchanger, but the relationship is non-linear. | [182] | |
-A polymer composite heat exchanger called a belt-and-tube heat exchanger. -The design is shown to perform similarly to a plate-and-rib heat exchanger, but uses less material. | [183] | ||
LOM | -Complex ceramic heat exchangers can be built using LOM processes. -The ceramic heat exchanger can be manufactured at a reasonable cost. | [184] | |
LCM | -The creation of complex designs using LCM was demonstrated. -Components with over 99% post-sinter density were obtained | [185] | |
-LCM has enabled the production of alumina and zirconia components. -A heat transfer area of more than 3500 mm2 and holes as small as 0.2 mm in diameter can be achieved. | [139] |
Application | 3D Printing | Materials | Reference |
---|---|---|---|
Fuel cells and electrolyzers | SLA, EFF, DIW | Electrode materials, stabilized zirconium electrolytes (lanthanum-based perovskite oxides and nickel-based composites), glass sealants | [187,188,189,190,191,192,193,194,195] |
DIW, SLS | Polymer electrolytes (nafion) and electrodes (precious metals), metallic metallics (stainless steel) | ||
Solar cells | DIW, R2R, IL | Current collectors (silver, copper, tin, indium), carriers (polymers), cells (P3HT: PCBM, organic perovskites, CIGS) | [196,197,198,199,200,201,202,203,204] |
Thermoelectric cells | EFF, DIW, SLS, SLA | Bi2Te3, BiSbTe, Cu2Se, PbTe | [205,206,207,208,209,210,211,212,213] |
Batteries | DIW, EFF | Polymer electrolytes (PVDF-co-HFP), electrodes (LiFePO4-LPF, Li4Ti5O12-LTO, graphene oxide composites) | [214,215,216,217,218,219,220,221,222,223] |
Supercapacitors | DIW, EFF | Polymer electrolyte (KOH/polyvinyl alcohol), electrodes (activated carbon, Ti3C2Tx MXene nanosheets, manganese dioxide nanowires, silver nanowires, and fullerene), current collector (Ag nanoparticles), package (polypropylene) | [224,225,226,227,228,229,230,231,232] |
Rotating Machines | DED, SLS | Ti alloys, Ni-based superalloys, high-temperature Fe-based alloys, Ti or Fe-based intermetallic materials | [233,234,235,236,237] |
Chemical reactors | DIW, DLP, EFF | Reactor (stainless steel, aluminum oxide), catalyst carrier (metal oxides), catalyst (precious metals) | [238,239,240,241,242,243,244,244,245] |
Solid-state refrigerators | SLS, DED, EFF, DIW, SLA | Ferroelectric/ferromagnetic/ferroelastic caloric materials | [246,247,248,249,250,251,252,253] |
CO2 capture and separation | SLS | Metals or alloys with high thermal conductivity (Aluminum AlSi10Mg) | [254,255,256,257,258,259,260] |
Electronics Cooling | SLS | Metals or alloys with high thermal conductivity (Al-Si10Mg, Al 6061, CuNi2SiCr) and polymer composites | [261,262,263,264,265,266,267] |
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Anwajler, B. Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective. Inventions 2024, 9, 60. https://doi.org/10.3390/inventions9030060
Anwajler B. Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective. Inventions. 2024; 9(3):60. https://doi.org/10.3390/inventions9030060
Chicago/Turabian StyleAnwajler, Beata. 2024. "Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective" Inventions 9, no. 3: 60. https://doi.org/10.3390/inventions9030060
APA StyleAnwajler, B. (2024). Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective. Inventions, 9(3), 60. https://doi.org/10.3390/inventions9030060